Expandable Stud Bracket

ABSTRACT

An expandable stud bracket for attachment to a board for construction of a temporary structure of support is disclosed. An embodiment of the bracket includes a receiving portion for securing the bracket to a stud, an adjustable portion opposite the receiving portion and having an extendable rod, an engagement plate attached to an end of the rod and an anchor attached to an end of the rod opposite the engagement plate and for limiting extension of the rod from the bracket, and a locking mechanism attached to the rod for preventing retraction. Optionally, a tensioning mechanism, such as a Belleville washer may be used in a key location to “self-adjust” for shrinkage or tension loss. An embodiment of the disclosed bracket may be attached between two boards to permit better access to the locking mechanism. A reusable fastener is also disclosed.

RELATED APPLICATIONS

The present application is a continuation-in-part of U.S. patentapplication Ser. No. 13/488,041 titled “Expandable Stud Bracket” andfiled on Jun. 4, 2012. This application also claims the filing priorityof U.S. Provisional Application No. 61/960,004, filed Sep. 9, 2013, andtitled “Options And Accessories To An Expandable Bracket For Temporary2×4 Installation.” The entirety of the '004 provisional application ishereby incorporated by reference.

TECHNICAL FIELD OF THE INVENTION

The present device and system relate to building materials for erectingtemporary walls. Particularly, the present device and system relate toan expandable bracket to facilitate construction of a temporary wall orwork-space.

BACKGROUND OF THE INVENTION

In the construction field, the need for installation of temporary wallsand studs (vertical and horizontal) often arises. Some of theseoccurrences are expected and some unexpected. Regardless, erecting thesetemporary structures can add considerable cost and time to aconstruction project. The frequency of the need for such structuresappears to be on the increase.

For example, as a result of new Federal construction laws, dust controlwalls are now required under certain circumstances. Specifically, acontractor/remodeler must contain and isolate any area where lead-basepaint may be present prior to cutting and removing walls or ceilingmaterial from the structure. This law applies to any home, school, orday care facility built before 1978, where the presence of lead-basedpaint must be assumed and tested for before work can be performed.

Similarly, some construction projects require the installation oftemporary studs. When an existing wall is being prepared to be removed,the ceiling structure above must be temporarily supported. This iscommonly accomplished by installing a temporary 2″×4″ stud under eachceiling support joist. When done properly, installation of the temporarywall can require as much time and energy as construction of a permanentwall.

The systems that are currently available are designed solely to supportthe weight of plastic for dust control. These systems are not designedto support the weight that would be required for a temporary supportstructure. Many of these dust control systems consist of round metaltelescoping poles which are designed to hold the plastic at the ceiling.Adhering the plastic to the round pole is cumbersome and expensive whenusing additional material such as painter's tape. Additionally, the polesystem is somewhat expensive to have sufficient supports.

The present invention addresses and solves these and other problemsassociated with the construction of temporary structures. By providing adevice and a system which can be quickly installed, the presentinvention reduces the time, cost and energy required for construction oftemporary structures.

SUMMARY OF THE INVENTION

There is disclosed herein in adjustable stud for the construction of atemporary structure which avoids the disadvantages of prior deviceswhile affording additional structural and operating advantages. Theadjustable stud system is reliable, sturdy, and reusable.

In a first embodiment, the expandable stud bracket comprises a receivingportion for securing the bracket to a stud, an adjustable portionopposite the receiving portion and having an extendable rod, anengagement plate attached to an end of the rod and an anchor attached toan end of the rod opposite the engagement plate and for limitingextension of the rod from the bracket, and a locking mechanism attachedto the rod for preventing retraction.

Optionally, a detachable foot portion may be used. Preferably, theextendable rod is threaded and the locking mechanism comprises a nutwhich can be tightened using a lever.

In an alternate embodiment, the bracket includes a detachable extendableplate mechanism and a housing with two ends for receiving boards.

In another alternate embodiment, the bracket includes a pair ofcomplementary wedges which allow support of an angled surface.

Further, a stud expansion system is disclosed comprising a housinghaving a plurality of sidewalls, a first open end, a second open end andan opening defined in a sidewall for accessing the interior of thehousing, an extendable plate mechanism comprising an anchor plate, anextension tube fixed to the anchor plate, an extension rod movablewithin the extension tube, and an engagement plate fixed to an end ofthe extension rod, and a locking mechanism for securing the extensionrod at a desired extended length.

These and other aspects of the invention may be understood more readilyfrom the following description and the appended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For the purpose of facilitating an understanding of the subject mattersought to be protected, there are illustrated in the accompanyingdrawings embodiments thereof, from an inspection of which, whenconsidered in connection with the following description, the subjectmatter sought to be protected, its construction and operation, and manyof its advantages should be readily understood and appreciated.

FIG. 1 is a perspective view of an embodiment of the present bracketsystem;

FIG. 2 is a perspective view of the embodiment of FIG. 1 in use;

FIG. 3 is a close up perspective view illustrating the movement of anembodiment of the engagement plate of a bracket;

FIGS. 4 a and 4 b are views of a safety feature and thumb lift used inembodiments of the present invention;

FIG. 5 a is a perspective view of an embodiment of the bracket systemillustrating storage of a foot portion;

FIG. 5 b is a back side view of the embodiment of FIG. 5 a;

FIG. 6 is an exploded perspective view of another embodiment of abracket system;

FIG. 7 is a perspective view of an embodiment of a stud sleeve forreceiving and retaining two studs;

FIG. 8 is a perspective view of another embodiment of a bracket system;

FIG. 9 is a perspective view of another embodiment of a bracket systemuseful for angled surfaces;

FIG. 10 is a perspective view of another embodiment of a bracket systemsimilar to that shown in FIG. 9;

FIG. 11 is a perspective view of the embodiment of FIG. 9 attached to anangled surface; and

FIG. 12 is perspective view of another embodiment of an expandablebracket;

FIG. 13 is a perspective view of a Bellville washer;

FIG. 14 is an isometric view of still another embodiment of anexpandable bracket;

FIG. 15 illustrates the expandable bracket of FIG. 14 is one possibleuse;

FIG. 16 is a close up of an embodiment of a reusable fastener and whereit might be used in the disclosed system; and

FIG. 17 is a close up of an alternate embodiment of a reusable fastener.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

While this invention is susceptible of embodiments in many differentforms, there is shown in the drawings and will herein be described indetail a preferred embodiment of the invention with the understandingthat the present disclosure is to be considered as an exemplification ofthe principles of the invention and is not intended to limit the broadaspect of the invention to embodiments illustrated.

Referring to FIGS. 1-11, there is illustrated several embodiments of anexpandable bracket, generally designated by the numeral 10. Additionalembodiments and related components are similarly designated with theaddition of a 1, 2, 3, . . . etc. to distinguish between suchembodiments. The bracket 10 can be designed for attachment to an end ofa 2″×4″, 4″×4″, or 2″×6″ board, then the assembly is placed between twostationary surfaces, e.g., floor-to-ceiling, wall-to-wall, and expanded.The assembly may be used both horizontally and vertically with equalsuccess and is not limited to the few examples described and illustratedherein.

In the embodiment illustrated in FIGS. 1-6, the bracket 10 includes ahousing 12 comprised of sidewalls 14, a top panel 15, and front and backpanels 16 a-b, and an expansion mechanism 18 (Note: the back panel 16 bis shown in broken lines in FIG. 1 to allow better viewing of thebracket interior). The bottom of the housing 12 is left open forreceiving the end of a board. Holes 13 defined within the sidewalls, andtop, front and back panels allow nails and/or screws (not shown) toretain the board within the open end of the bracket 10. An internal stop20 is used to halt the insertion of the board so as not to interferewith the operation of the expansion mechanism 18. Window 11 (FIG. 2) ispreferably defined within the front panel 16 a to allow the user tovisually ascertain when a board is inserted sufficiently to contact stop20.

Referring to FIG. 3, the expansion mechanism 18 is positioned at the topof the bracket 10 and includes an engagement plate 21, an extension rod,and an anchor 24. The engagement plate 21 is preferably fixed, via aweld or other means, to one end of the extension rod 22, while theanchor 24 is likewise fixed to the other end of the rod 22. In variousof the disclosed embodiments, the engagement plate 21 and/or the anchor24 may include holes for securing to a surface via nails or screws. FIG.6 illustrates edge slots on engagement plate 21 for “toe-nailing” to asurface.

An opening in the top panel 15 and a guide 25 positioned within thehousing 12, retain the extension rod 22 in a position to move only in adirection perpendicular to the top panel 15. The guide 25 is preferablyprovided by cutting three sides of a rectangular section of the frontpanel 16 a and bending it into the housing interior, leaving an opening17 on the front panel 16 a of housing 12. The guide 25, which iscompleted with a hole therein to retain the extension rod 22, alsoprovides a limit to the upward movement of the rod 22 by stopping theanchor 24 from further travel. The rod 22 otherwise moves freely withinthe holes of the top panel 15 and guide 25.

Preferably, the expansion mechanism 18 provides about 0.5 inches toabout 6 inches of adjustability. Most preferably, the adjustability islimited to a range of from about 0.75 inches to about 2.0 inches. In apreferred embodiment, shown in FIGS. 4 a-b, the expansion mechanism 18is extended manually through opening 17 in front panel 16 a. The anchor24 is provided with a tab 45 which extends through the opening 17 and aprotective cover 46 which prevents the user from placing anything,especially fingers, under the anchor 24. As the anchor 24 is raised viatab 45, the protective cover 46 blocks the opening 17. This is not onlyan important safety feature for the illustrated embodiment, but a usefulfeature for more readily extending the engagement plate 21. The tab 45allows a user to use one hand to raise and hold the plate 21 in place,while adjusting locking mechanism 26 with the other hand.

Also shown in FIGS. 1-3 is locking mechanism 26 attached to the rod 22to lock the downward travel of the rod 22, and thus the engagement plate21. For ease of access and structural integrity, the locking mechanism26 is positioned outside the bracket housing 12 to abut the top panel 15in use. However, it may be alternately positioned within the housing 12to abut the guide 25 or another surface. In the illustrated embodiment,the rod 22 is a threaded rod and the locking mechanism 26 is a knurledfinger nut 30 threaded onto the rod 22.

The nut 30 is also preferably provided with lever slots 31 to facilitatetightening of the locking mechanism 26. The slots 31 are merely roundopenings into which a tool may be inserted for added leverage to torquenut 30 to be either tightened or loosened on rod 22. Specifically forthis purpose, a lever 32 may be provided as part of a stud expansionsystem. The lever 32 is preferably metal and round (in cross-section)with a length sufficient to allow turning of the nut 30 withoutimpacting the user's hands (e.g., knuckles) on the housing 12 edges. Thelever 32 may also be stored on or within the housing 12 using by addinga slot (not shown) or magnets (not shown).

As an optional feature of the bracket system 10, a detachable foot 34may be provided. The foot 34 is preferably a U-shaped device havingnail/screw holes defined therein. A rubber pad 35 may also be providedon a contacting surface of the foot 34. The foot 34 may be used in oneof two ways.

The foot 34 may be secured to an opposite end of a board within thebracket 10. This allows the padded side of the foot 34 to contact othersurfaces without marring, scratching or moving. Alternatively, the foot34 may be inverted and secured by nail/screw to the opposite end of theboard within the bracket 10, via the padded surface, and also secured bynail/screw to a perpendicular board via the arms of the foot 34. Thelatter configuration is preferably used whenever the support board isbeing attached to a perpendicular board. A notch 37 may optionally beprovided in the foot 34, as shown in FIG. 5 a, to allow storage duringnon-use.

In use, with reference to FIG. 2, an end of a board of the properdimensions is first secured within the receiving end of the bracket 10using the defined sidewall holes and nails or screws. Similarly, thefoot 34 may be optionally attached to the opposite end of the board, asdescribed above. The expansion mechanism 18 is then manually extended toa distance just less than the span in which the temporary stud is to beplaced. This is done by extending out the engagement plate 21 by liftingthe anchor 24. The nut 30 is then easily spun to engage the top panel 15of housing 12.

The assembly can then be positioned properly in the desired space andthe lever 32 can be inserted into a slot 31 and used to turn the lockingmechanism 26 to thereby further extend the extension rod 22 andengagement plate 21 until sufficient support is achieved. At all timeswhile turning the locking mechanism 26/nut 30, the anchor 24 preventsturning of the threaded rod by contacting the housing 12.

If necessary, to remove or reposition the temporary stud assembly, thelever 32 may be inserted into a slot 31 and used to turn the lockingmechanism 26 in an opposite direction until contact between theengagement plate 21 and opposing surface is lost. The assembly may thenbe repositioned and retightened or disassembled and stored.

Referring to FIGS. 6-8, several features of alternate embodiments of thepresent invention, bracket system 110, are illustrated. In theseembodiment, the housing 112 is open on both ends to receive a board inone end and the expansion mechanism 118 in the other. Here the expansionmechanism 118 is manufactured as a separate component from the housing112 and attaches to the housing 112 via tabs 140 inserted within slots141. This configuration may be best utilized where a less expensiveplastic molded housing 118 is used, for example.

Similar to previous embodiments, the expansion mechanism 118 of FIG. 6comprises an engagement plate 121, an expansion rod 122, and an anchorplate 124, but also includes an expansion tube 125 fixed to the anchorplate 124. The attachable expansion mechanism 118 may be positionedwithin the housing 112 by snap-fitting the tabs 140 within slots 141,where they may not be removed without destroying housing 112. The anchorplate 124 rests on stop 120 for further support. As with the previousembodiment described above, the rod 122 may be manually extended and thelocking mechanism 126 tightened to prevent inward movement of the rod22. The expansion tube 125 is preferably keyed to the expansion rod 122or otherwise configured to prevent turning of the expansion rod 122 whenengaging locking mechanism 126.

Alternatively, the tube 125 may include internal threads to engage thethreaded expansion rod 122. The engagement plate 121 and rod 122 wouldrequire turning to extend the mechanism to a desired length. No lockingmechanism would be required.

In either configuration, the anchor plate 124 includes holes therein forinsertion of nails or screws for attachment to a board inserted in theopposite end of housing 112. As shown in FIG. 8, a possible alternateuse for the illustrated embodiment may include attachment of themechanism 118 to a board end and insertion of boards into both ends ofthe housing 112.

Optionally, a detachable foot 134 may also be provided. By providingstorage slots 142 on housing 112, the arms of foot 134 may be insertedinto the slots 142 for storage of the foot during non-use. Magnets fixedto the bracket housing 112 may be used to provide a more positiveretention of the stored metal foot 134.

In use, the bracket system 110 of FIG. 8 may allow a greater span forinstallation by using a board inserted at both ends of the housing 112.The expansion mechanism 118 attaches by the anchor plate 124 to a freeend of one of the boards, while the optional foot attaches to a free endof the other board. The expansion mechanism 118 is extended to adistance slightly less than the necessary distance and then positionedwhere needed. The engagement plate 121 can then be further extended tocontact and sufficiently support the opposing surface by either turningthe locking mechanism 126 or the engagement plate 121, as required.

FIG. 7 illustrates a sleeve 102 which provides a user with the abilityof using, for example, two 4 ft boards (or some variation of two boardsmeasuring 8 ft total) instead of one 8 ft board. Window 117 providesvisual assurance of the two boards proper seating in sleeve 102. Eitherof the free ends of the two boards may then be used with the bracketsystem 10/110 as described above.

FIGS. 9-11 illustrate still another embodiment of the invention, bracketsystem 210. This bracket 210 is suitable for use on flat and slopedsurfaces, such as a vaulted ceiling. The bracket 210 is comprised ofhousing 212 and base 221. The housing 212 includes a receiving end forattachment to a board via bolt 250 and wing nut 251 positioned withinslot 232. The slot 232 allows the attached board to move a distance andpivot within the housing 12. The base 221 includes complementary wedges,specifically stationary wedge portion 260 having an approximately 45°surface and a movable wedge portion 262 also having an approximately 45°surface—the individual angles may vary, so long as the resultingcombined angle of the two wedges is at least 90°. The movable wedge 262is configured to slide along the stationary wedge 260 to adjust theangle of the secured board relative the base 221. A dovetail connectoris illustrated in FIG. 9, while a channel 263 and bolt 264 connection isshown in FIG. 10. Numerous alternate connection configurations arepossible.

In use, a board is inserted into the open end of housing 12 and securedwith bolt 250 and wing nut 251—a hole may need to be drilled first. Theassembly is positioned where needed with the base surface 221 facing thesurface to be supported. The position of board in housing 12 may beadjusted by loosening and retightening the bolt 250 and wing nut 251.The movable wedge 262 can then we slid between stationary wedge 260 andthe end of the board until a desired angle within the range of fromabout 10 to about 90 degrees is achieved. As shown in FIG. 11, the base221 may include a screw hole for securing the base 221 to the surfacebefore setting the bolt 250 and wing nut 251.

FIG. 11 illustrates a double-hook 263 attached to the base 221. Where aplurality of supports need to be constructed, a string line 266 may berun between two brackets 210, as is known in the art, to align a seriesof bases 221. As previously described, the bases 221 may be attached viathe screw hole before insertion of a board

Referring now to FIGS. 12-17, additional embodiments and accessories tothe expandable bracket 10 are shown.

Under certain conditions a 2″×4″ board used along with an embodiment ofthe expandable bracket 10 may shrink slightly during use, especially indry conditions when the system is in place over a long period of time.The following improvement will help compensate for the potentialshrinkage.

In an embodiment, the shrinkage is compensated by spring loadingelements of the bracket 10 so they “self-adjust” under a release oftension (which would occur from shrinkage). Location 300, under the nut26 of the treaded rod 22, is one example where spring-loading can beuseful. The type of spring used may vary, including a common coil spring(not shown) or a Belleville washer (or spring washer) 301, as shown inFIG. 13. In the case of the Belleville washer 301, one or more may beused, with additional washers being stacked as is well-known in the art(i.e., front to front and back to back) on the threaded rod 22. Thistype of arrangement creates space for the cupped washers to collapseunder a load and then regain their cupped shape after the load isrelieved. The varied tension created and maintained by the springwasher(s) may occur either in response to shrinkage or when the bracketnut 26 is loosened for removal. Alternatively or additionally, otherareas of the bracket 10 may be spring loaded, such as under the topplate or inside the main housing at positions 302 (FIG. 12) where thestud slides into the bracket 10.

Another embodiment of the bracket 10 may be used between two shorter2″×4″ studs, as shown in FIG. 14, as opposed to being at the top orbottom of the stud, as previously disclosed. This embodiment is similarto that shown in FIG. 7 which shows a sleeve for connecting two lengthsof 2″×4″ boards. Arrows 304 illustrate where the 2″×4″ would be insertedand fastened in place with screws, nails, etc. through holes 13. Arrow305 shows the direction of travel the two housings are allowed to movein. The two housings would be connected by guides 306 which arecomprised of slots on one housing and a pin in the other to keep the twohousing brackets aligned. These guides and/or slots may be various sizesand may also be located on the narrow or wide side of the brackets.

Referring to FIG. 15, by positioning the adjustment mechanism of thesystem within the reach of a user, it would allow the tightening andloosening in place without the need for a ladder. Padded ends (see FIG.5A, components 21 and 34) could still be attached at the top and thebottom of the stud, as previously disclosed.

FIGS. 16 and 17 show two embodiments of a reusable fastener 307 forholding sheet-like materials such as plastic, cloth, Tyvek, etc. inplace over a 2×4 framework created using the disclosed expandablebracket 10. The pointed ends 310 of the fastener 307 are easily driveninto a wood substrate, such as a stud. FIG. 16 also illustrates atypical wood framework where these fasteners would be used along itslength. The temporary installation of such materials is necessary whenthe expandable bracket 10 is being used for dust control or containmentor to visually separate two spaces. Current means for holding thesematerials in place are staples, nails, screws, etc. When a standardstaple is used, it may be difficult to remove and/or it may even tearthrough a plastic sheet. Nails into wood are also hard to remove. Screwsmay also pull through the sheet material or may twist a fabric typesheet.

The fastener 307 of FIG. 16 will not only hold the material in place butis also designed to be removed easily with a flat screw driver, pry bar,or the like, placed within one of the openings 308 to pry against.Furthermore, the large profile and the contours 309 of the fastener 307facilitate holding and positioning by an individual using their fingersprior to it being tapped into place with a hammer. Conversely, smallertype nails are hard to hold along a narrow one to two inch width of astud, especially when it is installed tight against a perpendicularsurface such as a wall. The fasteners 307 are also designed to bereusable.

The fastener 307 of FIG. 17 shows the addition of a hole 311 through thefastener body for the option of holding it in place with a nail orscrew, if desired.

The matter set forth in the foregoing description and accompanyingdrawings is offered by way of illustration only and not as a limitation.While particular embodiments have been shown and described, it will beapparent to those skilled in the art that changes and modifications maybe made without departing from the broader aspects of applicants'contribution. Specifically, several of the disclosed features of thepresent invention are described and illustrated with some embodimentsand not others. Such examples are intended to be descriptive of thefeatures and not limiting of the possible embodiments. It should beunderstood that all the disclosed features may be provided in any of thedescribed embodiments, as desired. The actual scope of the protectionsought is intended to be defined in the following claims when viewed intheir proper perspective based on the prior art.

What is claimed is:
 1. An expandable stud bracket comprising: areceiving portion for securing the bracket to a stud; an adjustableportion opposite the receiving portion and comprising an extendable rod,an engagement plate attached to an end of the rod and an anchor attachedto an end of the rod opposite the engagement plate and for limitingextension of the rod from the bracket; and a locking mechanism attachedto the rod for preventing retraction.
 2. The expandable bracket of claim1, further comprising a detachable foot portion.
 3. The expandablebracket of claim 1, wherein the extendable rod is threaded and thelocking mechanism comprises a nut.
 4. The expandable bracket of claim 1,further comprising a tensioning mechanism positioned at one of eitherwithin the receiving portion at an interface with the stud and at aninterface between the receiving portion and the locking mechanism. 5.The expandable bracket of claim 4, wherein the tensioning mechanismcomprises at least one Belleville washer.
 6. A stud expansion systemcomprising: a housing having a plurality of sidewalls, a first open end,a second open end and an opening defined in a sidewall for accessing theinterior of the housing; an expansion mechanism comprising an anchorplate, an extension tube fixed to the anchor plate, an extension rodmovable within the extension tube, and an engagement plate fixed to anend of the extension rod; and a locking mechanism for securing theextension rod at a desired extended length.
 7. The stud expansion systemof claim 5, wherein the housing further comprises a plurality of holesdefined in at least one of the plurality of sidewalls through which astud may be secured within at least one of the first open end and thesecond open end via a nail or screw.
 8. The stud expansion system ofclaim 5, further comprising a detachable foot having a mounting surfacehaving a least one hole defined therein for securing the foot to an endof a stud via a nail or screw.
 9. The stud expansion system of claim 5,further comprising a lever for tightening the locking mechanism.
 10. Thestud expansion system of claim 7, wherein the detachable foot furthercomprises a pad attached to the mounting surface.
 11. The stud expansionsystem of claim 7, wherein the detachable foot comprises a notch in themounting surface for storage about the extension rod.
 12. The studexpansion system of claim 5, wherein the anchor plate comprises at leastone hole for securing to a stud via a nail or screw.
 13. A reusablefastener comprising: a body having a top surface, a bottom surface and aplurality of sides which together define a width, length and height ofthe body; at least two pointed and parallel extensions from the bottomsurface of the body; wherein the body comprises contoured sides tofacilitate grasping with fingers and at least one gap opening along aside immediately adjacent the bottom surface to facilitate insertion ofa tool between the body and a substrate into which the fastener has beeninserted.